KR20150017715A - Durable solar mirror films - Google Patents

Abstract

The present invention relates generally to durable sun mirror films, methods for making durable sun mirror films, and structures comprising durable sun mirror films. Some embodiments of the present invention are directed to a method of making a sun mirror film that does not include a reflective layer material across the entire weatherable layer. Some embodiments include providing a weather resistant layer 220 having a first major surface and a second major surface; Depositing a reflective material (240) on the first major surface of the weatherable layer; And removing portions (230a - 230d) of the reflective material (240) by ultrasonic or thermally.

Description

DURABLE SOLAR MIRROR FILMS

US government license

The US Government has rights to at least some of the invention described in this patent application in accordance with DE-AC36-08 GO28308 (CRADA No. 08-316), awarded by the US Department of Energy.

The present invention generally relates to durable solar mirror films, methods for making durable sun mirror films, and structures comprising durable sun mirror films.

Renewable energy is energy derived from natural sources that can be supplemented, such as sunlight, wind, rain, tides, and geothermal heat. The demand for renewable energy is increasing substantially due to the development of technology and the increase in world population. Fossil fuels supply most of the energy consumption today, but these fuels are not renewable. The global dependence on these fossil fuels has environmental problems associated with emissions that are produced by burning these fuels as well as increased problems associated with their depletion. As a result of these problems, countries around the world have developed plans to develop both large and small renewable energy sources. One of the promising energy resources today is solar. Worldwide, millions of homes now derive power from photovoltaic systems.

Generally, concentrated solar technology involves the collection of solar radiation to generate electricity directly or indirectly. The three main types of convergent solar technology are concentrated photovoltaic, concentrated solar power, and solar thermal technology.

In centralized photovoltaic (CPV) technology, concentrated sunlight is converted directly into electricity through photovoltaic effects. Generally, the CPV technique uses an optical article (e.g., a lens or mirror) to concentrate a large amount of sunlight onto a small area of the photovoltaic material to generate electricity. CPV systems are often much less costly than other types of photovoltaic energy generation, because the concentration of solar energy allows much less expensive solar cells to be used.

In centralized solar power (CSP) technology, concentrated sunlight is converted to heat and then heat is converted to electricity. Generally, CSP technology uses a mirrored surface of multiple geometries (e.g., a flat mirror, a parabolic dish, and a parabolic trough) to focus solar light on the collector. Which in turn ultimately heats the working fluid (e.g., synthetic or molten salt) or drives a heat engine (e.g., a steam turbine). In some cases, the operating fluid drives an organs generating electricity. In other cases, the working fluid passes through a heat exchanger to produce steam, which is used to power the steam turbine to generate electricity.

The solar system collects solar radiation to heat the water, or to heat the process stream in an industrial plant. Some solar designs use reflective mirrors to focus sunlight on a collector that houses water or a feed stream. The principle of operation is very similar to that of a centralized solar power unit, but the concentration of sunlight and the resulting operating temperature are not that high.

The increased demand for solar power has accompanied the increased demand for reflectors and materials that can meet the requirements for these applications. Some of these solar reflector technologies include glass mirrors, aluminum-treated mirrors, and metal-treated polymer films. Of these, metal treated polymer films are particularly attractive because they are lightweight, provide design flexibility, and are potentially less costly than conventional glass mirrors. The polymer is lightweight, inexpensive, and easy to manufacture. To achieve metal surface properties on the polymer, a thin layer of metal (e.g., silver) is coated on the polymer surface.

One exemplary commercially available solar mirror film is schematically illustrated in Fig. The solar mirror film 100 of Figure 1 includes a premask layer 110, a weatherable layer 120 (including, for example, a polymer), a thin, sputter-coated tie layer 140, A reflective layer 150 (including reflective metal such as silver), a corrosion resistant layer 160 (including, for example, a metal such as copper), an adhesive layer 170, and a liner 180). Typically, the film of Figure 1 is applied to the support substrate by removing the liner 180 and placing the adhesive layer 170 adjacent the support substrate. The preliminary mask layer 110 is then removed to expose the weather resistant layer 120 to sunlight.

Metal-treated polymer films used in concentrated solar power units and concentrated photovoltaic solar systems are continuously exposed to bad weather. As a result, the technical challenge in designing and manufacturing metal-treated polymeric reflective films is to achieve long term (e.g., 20 years) durability upon exposure to harsh environmental conditions. There is a need for a metallized polymer film that once installed in a centralized solar power unit or lumped photovoltaic cell provides durability and optical performance to be maintained (e.g., reflective). Mechanical properties, optical transparency, corrosion resistance, ultraviolet light stability, and resistance to outdoor climatic conditions all contribute to the gradual deterioration of materials over long periods of operation.

The inventors of the present invention have found that a number of technical problems in forming a durable, metallized polymer film that can be used outdoors for extended periods of time to maintain optical performance are due to a fundamental mismatch of the physical and chemical properties and properties of the metal and polymer . One particular difficulty relates to ensuring good adhesion between the polymer layer and the metal reflective surface. If good adhesion is not achieved between these layers, delamination occurs. The delamination between the polymer layer and the metal layer is often referred to as "tunneling ".

The inventors of the present invention have recognized that delamination typically occurs due to reduced adhesion between the polymer layer and the metal layer. This reduced adhesion can be caused by any one of a number of factors, and often by a combination of these factors. Some exemplary factors recognized by the inventors of the present invention include (1) increased mechanical stress between the polymer layer and the metal layer; (2) oxidation of the metal layer; (3) oxidation of the adhesive adjacent to the metal layer; And (4) deterioration of the polymer layer (which may be due, for example, to exposure to sunlight). Each of these factors includes, for example, environmental temperature (including variations in ambient temperature), thermal shock, humidity, exposure to moisture, exposure to air impurities such as, for example, salts and sulfur, UV exposure, , ≪ / RTI > and product storage.

One of the most difficult problems is related to the stress at the metal / polymer interface. If the stress is too great, buckling may occur, which may cause the polymer layer to delaminate from the metal layer. In addition, when the metal-treated polymer film is cut, its edge may be ruptured or unprotected. This combination of ruptured and exposed metal edges and the net interfacial stress listed above can lead to adhesion strength and can cause tunneling since corrosion of the metal treated polymer begins at its edge. The inventors of the present invention have recognized that it is important to protect the interface between the polymer layer and the metal layer, particularly along the edge of this interface.

Two prior art approaches have been used to address these problems. First, a sealing caulk was applied around the edge of the metallized film. Second, a tape was wrapped around the edge of the metallized film. If properly applied, both of these approaches are effective in minimizing short term delamination and / or tunneling. Disadvantageously, however, both of these approaches reduce the total available reflective area. Also, disadvantageously, both of these approaches introduce separate materials into the front surface of the metallized film, which creates ridges or protrusions above and below the plane of the metallized film . These ridges or protrusions become areas of potential additional stress when the metallized film is exposed, for example, to wind and hail. This additional stress is increased during routine maintenance processes, including, for example, handling during use and cleaning (e.g., pressurized cleaning). In addition, the separate material must be adhered to the metallized film for the lifetime of the film so that it is effective over the lifetime (e.g., 20 years) of the metallized film. These materials were limited in their ability to do so.

The inventors of the present invention have recognized that the reflective layer in conventional sun mirror films extends across the entire weatherable layer. As discussed above, mismatching of the properties of these layers makes it easier for them to delaminate and tunnel at their interface, especially at the edge of the mirror film. Thus, the inventors of the present invention have recognized that sun mirror films with less or no silver along some or all of the edges of the sun mirror film exhibit increased durability and reduced delamination and / or tunneling.

The inventors of the present invention have also found a new way of forming a sun mirror film that has less, at least no, or no reflective material at the edge portion. For example, the inventors of the present invention have found a unique way of forming a sun mirror film as described herein using ultrasonic welding.

One embodiment of the present invention provides a method for forming a weather resistant layer, comprising: providing a weather resistant layer having a first major surface and a second major surface; Depositing a reflective material on the first major surface of the weather resistant layer; And removing the portion of the reflective material by ultrasonic waves.

Another embodiment of the present invention is a method of making a weather resistant layer, comprising: providing a weather resistant layer having a first major surface and a second major surface; Depositing a reflective material on the first major surface of the weather resistant layer; And thermally removing a portion of the reflective material. ≪ RTI ID = 0.0 > [0002] < / RTI >

In some embodiments, a portion of the reflective material removed from the weatherable layer follows one or more edge regions of the weatherable layer. In some embodiments, at least one of the edge regions extends from the distal edge of the weatherable layer to 2 mm above the first major surface. In some embodiments, the edge region extends from about 2 mm to about 20 mm from the distal edge of the weatherable layer onto the first major surface.

In some embodiments, the step of depositing the reflective material can be performed by any suitable method, including sputter coating, evaporation via e-beam or thermal methods, ion-assisted e-beam evaporation, electroplating, spray painting, vacuum deposition , And at least one physical vapor deposition through a combination thereof. In some embodiments, the reflective material covers at least 98% of the first major surface of the weatherable layer.

In some embodiments, the step of ultrasonically removing the reflective material includes using a knurl pattern. In some embodiments, the present invention further comprises the step of ultrasonically removing a portion of the weather resistant layer.

In some embodiments, the present invention further comprises the step of disposing a filler in the area from which the reflective material has been removed. In some embodiments, the filler is a polymeric material. In some embodiments, the filler is a thermoplastic material.

In some embodiments, the weather resistant layer comprises at least one of PMMA, polycarbonate, polyester, multilayer optical film, fluoropolymer, and blend of acrylate and fluoropolymer. In some embodiments, the reflective material comprises at least one of silver, gold, aluminum, copper, nickel, and titanium.

In some embodiments, the method further comprises the step of disposing a tie layer between the weather resistant layer and the reflective material. In some embodiments, the tie layer comprises an adhesive. In some embodiments, the method further comprises ultrasonically removing a portion of the tie layer.

In some embodiments, the method further comprises placing a polymeric material between the weather resistant layer and the reflective material. In some embodiments, the method further comprises the step of disposing a corrosion protection layer adjacent the reflective layer. In some embodiments, the corrosion protection layer comprises at least one of copper and an inert metal alloy.

In some embodiments, the present invention further comprises the step of placing the sun mirror film within at least one of a concentrated photovoltaic system, a concentrated solar system, or a reflector assembly, .

Other embodiments of the present invention are directed to a centralized solar power system that includes a sun mirror film as described herein, including but not limited to any of the above embodiments.

Another embodiment of the present invention is directed to a concentrated photovoltaic generation system comprising a sun mirror film as described herein, including, but not limited to, any of the above embodiments.

Various aspects and advantages of exemplary embodiments of the invention have been summarized. It is not intended to disclose each of the illustrated embodiments or all implementations of the invention. The following drawings and detailed description more specifically illustrate the various embodiments disclosed herein. These and various other features and advantages will become apparent upon reading the following detailed description.

≪ 1 >
1 is a schematic view of a prior art sun mirror film;
2,
2 is a schematic plan view of an exemplary embodiment of a sun mirror film according to the present invention;
3,
3 is a schematic plan view of another exemplary embodiment of a sun mirror film according to the present invention.
<Fig. 4>
4 is a schematic plan view of another exemplary embodiment of a sun mirror film according to the present invention.
5,
5 is a schematic plan view of another exemplary embodiment of a sun mirror film according to the present invention.

Some embodiments of the invention include a method of thermally removing at least a portion of a reflective material on a weather resistant layer. In some embodiments, a portion of at least one of the tie layer and the weather-resistant layer is also removed. Exemplary thermal removal methods include any thermal process including, but not limited to, ultrasonic removal (e.g., ultrasonic welding) and laser removal. The thermal removal process also includes a process of transferring energy through conduction, radiation, or convection.

Some embodiments of the present invention are directed to a method of making a sun mirror film that does not include a reflective layer material across the entire weatherable layer. Some embodiments of the present invention are directed to a method of making a sun mirror film that does not include a reflective material on at least one edge portion of the sun mirror film. Some embodiments of the invention relate to a method of making a sun mirror film having a reflective layer having discontinuities in the edge portions of the sun mirror films.

The methods described herein provide solar mirror films all of which are more durable. This increased durability is due, at least in part, to improved adhesion around the edge of the film as a result of direct contact between the weather-resistant layer and the adhesive layer. As a result, the occurrence of delamination or tunneling is minimized. At least, the adhesiveness is improved because the weather-resistant layer directly bonds to a layer other than the reflective layer (typically, the tie layer). The layer adhered to the weather-resistant layer and the weather-resistant layer has a bonding strength greater than that of the weather-resistant layer and the reflective layer.

An exemplary embodiment is shown in schematic plan view in Fig. The solar mirror film 200 of Figure 2 includes a weather resistant layer 210 that includes a bulk region 220 and four edge regions 230a, 230b, 230c, and 230d. The reflective material 240 is adjacent to the bulk region 220 of the weather-resistant layer 210. The reflective material 240 is largely (or substantially) absent from the edge regions 230a, 230b, 230c, and 230d. It will be appreciated by those skilled in the art that the reflective material 240 is substantially absent in all four edge regions 230 in the particular embodiment shown in Figure 2 but that the reflective material 240 is absent only in one or more edge regions Lt; / RTI &gt; As used herein, the term "substantially absent &quot; with respect to the fact that the reflective material is substantially absent in the edge region (s), means that the reflective material is absent at over 97% of the particular edge region.

As used herein, the term "edge region" refers to the region between one edge and the bulk region of the sheet. The edge region may be followed along the entire length or width of the sheet, but it may not. The size of the edge region may vary based on the particular application. However, the edge region may have any size large enough to form a bond strength between the adhesive layer and the weather-resistant layer, which exceeds the bond strength between the weather-resistant layer and the reflective layer.

Fig. 3 shows an embodiment in which there are no reflective materials in all four edge regions of the rectangular sheet. 3 shows a sun mirror film 300 comprising a weather resistant layer 210 comprising a bulk region 320 and edge regions 330a and 330b. The reflective material 240 is adjacent to the bulk region 320 of the weatherable layer 210. Reflective material 240 is largely (or substantially) absent in edge regions 330a and 330b.

Figure 4 shows an embodiment in which the edge regions do not extend along the entire length of the sun mirror film. 4 shows a sun mirror film 400 comprising a weather resistant layer 210 comprising a bulk region 420 and a number of edge regions 430. The reflective material 240 is adjacent to the bulk region 420 of the weather-resistant layer 210. The reflective material 240 is largely (or substantially) absent in the edge region 430. Thus, the reflective material is discontinuous along the edge of the sheet. The edge region in which the reflective material is substantially absent may be of a random size (e.g., as shown in FIG. 4), or it may be of a size that forms a pattern (e.g., as shown in FIG. 5). Thus, the discontinuous portion can be in a patterned form (e.g., as shown in FIG. 4) or in a random form (as shown in FIG. 5, for example).

Figure 5 shows an embodiment in which the edge regions do not extend along the entire length of the sun mirror film. 5 shows a sun mirror film 500 comprising a weather-resistant layer 210 comprising a bulk region 520 and a number of edge regions 530. The weather- The reflective material 240 is adjacent to the bulk region 520 of the weather-resistant layer 210. Reflective material 240 is largely (or substantially) absent in edge region 530. Thus, the reflective material is discontinuous along the edge of the sheet.

For the sake of simplicity, the schematic diagram shown in Figs. 2-5 shows only the weatherable layer and the reflective material only. These embodiments and these disclosures, however, are not to be construed as limiting the scope of the present invention, for example, by providing a layer (e.g., a tie layer) between the weather resistant layer and the reflective layer and another layer comprising a layer above or below the weatherproof layer and / Is intended to be included within the sun mirror film. Each of the potential layers is described in more detail below.

In some embodiments, the edge regions lacking reflective material are adjacent (and in some cases, directly adjacent) to the tie layer or adhesive. In some embodiments, the edge regions lacking the reflective material are adjacent (and in some cases, directly adjacent) to the polymer layer. Some exemplary polymer layers include, for example, PMMA layers, PVDF layers, and blends thereof.

In some embodiments, removal of reflective material creates a recessed area. In some embodiments, these recessed areas are filled with a filler material. In some embodiments, the filler material is a polymer. In some embodiments, the polymer is a thermoplastic material.

Thermal removal of the reflective material can be achieved by an ultrasonic process. In some embodiments, the ultrasonic process uses a null pattern. In some embodiments, the polymer material is heated by the absorbed vibration energy and the reflective material is dispersed. Ultrasonic heating can be applied over a range of pressures, frequencies, powers, and amplitudes. The amount of energy absorbed by the material depends on the process conditions, the physical properties of the material, the mechanical design of the nest (anvil) and the sonotrode (horn). The anvil design may vary in profile, width, and material. The advantages of the ultrasonic process are that the heating time and the cooling time are relatively short compared to the heating press.

Thermal removal of reflective material can be achieved by laser ablation. In some embodiments, at low laser flux, the reflective material is heated and evaporated or sublimated by the absorbed laser energy. In some embodiments, at a higher laser flux, the reflective material is converted to a plasma. The laser ablation can be a pulsed laser or a continuous wave laser beam, or a combination of both. The depth at which the laser energy is absorbed, and thus the amount of material removed by a single laser pulse, depends on the optical properties of the material and the laser wavelength. Laser pulses can vary over a very wide range of durations (milliseconds to femtoseconds) and fluxes. One advantage of using laser ablation is that the laser output can be precisely controlled.

The spare mask layer

The spare mask layer is optional. The preliminary mask, if present, protects the weatherable layer during handling, lamination, and installation. Such configurations can then be conveniently packaged for transportation, storage, and consumer use. In some embodiments, the reserve mask is opaque to protect the operator during outdoor installation. In some embodiments, the spare mask is transparent, allowing investigation of defects. Any known preliminary mask may be used. One exemplary commercially available spare mask is ForceField 占 1035 sold by Tredegar, Richmond, Virginia, USA. The spare mask layer may be located, for example, as shown in FIG.

Weatherable layer

In some embodiments, the weatherable layer or sheet is flexible and transparent to visible light and infrared light. In some embodiments, the weatherable layer or sheet is resistant to degradation by ultraviolet (UV) light. In some embodiments, the phrase "resistant to degradation by ultraviolet light" means that the weather-resistant sheet reflects at least 50% of incident ultraviolet light over a range of at least 30 nanometers in a wavelength range of at least 300 nanometers to 400 nanometers, Absorbing &lt; / RTI &gt; Photo-oxidative degradation caused by UV light (e.g., in the range of 280 to 400 nm) may result in degradation of the optical and mechanical properties of the polymer film and color change. In some embodiments, the weather-resistant sheet or layer is generally abrasion resistant and impact resistant and can prevent deterioration of the solar assembly when exposed to extreme outdoor weather, for example.

In some embodiments, the weatherable layer comprises at least one organic film-forming polymer. Some exemplary polymers include, for example, polyesters, polycarbonates, polyethers, polyimides, polyolefins, fluoropolymers, and combinations thereof. The assembly according to the present invention comprises a weather-resistant sheet or layer, which may be a single layer (single layer embodiment) or may comprise more than one layer (multi-layer embodiment).

Various stabilizers may be added to the weather resistant sheet to improve the resistance to UV light. Examples of such stabilizers include at least one of an ultraviolet absorber (UVA) (e.g., a red shift UV absorber), a hindered amine light stabilizer (HALS), or an antioxidant. These additives are described in further detail below. In some such embodiments, the weatherable sheet need not comprise UVA or HALS.

The UV resistance of weathering sheets can be evaluated, for example, using an accelerated weathering study. Accelerated environmental degradation studies are generally performed in accordance with ASTM G-155, "Standard Practice for Exposing Non-Metallic Materials to Facilitation Test Devices Using Laboratory Light Sources" ), &Lt; / RTI &gt; One mechanism for detecting changes in physical characteristics is to use a D65 light source operating in a weathering cycle and reflected mode as described in ASTM G155. Under the mentioned test, and when applying the UV protection layer to the article, the article has a b * value obtained using a CIE L * a * b * space before significant cracking, peeling, delamination or haze commences Must exceed 18,700 kJ / m ² exposure at 340 nm before increasing to less than 5, less than 4, less than 3, or less than 2.

In some embodiments, the weather resistant sheet comprises a fluoropolymer. Typically, fluoropolymers are resistant to UV degradation even in the absence of stabilizers such as UVA, HALS, and antioxidants. Some exemplary fluoropolymers include but are not limited to ethylene-tetrafluoroethylene copolymer (ETFE), ethylene-chloro-trifluoroethylene copolymer (ECTFE), tetrafluoroethylene-hexafluoropropylene copolymer (FEP) (PFA, MFA), tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymer (THV), polyvinylidene fluoride homopolymers and copolymers (PVDF), ethylene-perfluoro vinyl ether copolymers Blends of these, and blends of these and other fluoropolymers. The fluoropolymer is typically a homopolymer of TFE, CTFE, VDF, HFP or other fully fluorinated, partially fluorinated, or hydrogenated monomers such as vinyl ether and alpha-olefins, or other halogen containing monomers Or copolymers. Typically, the CTE of a fluoropolymer film is higher than that produced from a hydrocarbon polymer. For example, the CTE of the fluoropolymer film may be 75, 80, 90, 100, 110, 120, or 130 ppm / K or higher. For example, the CTE of ETFE may range from 90 to 140 ppm / K.

Weather-resistant films comprising fluoropolymers can also include non-fluorinated materials. For example, a blend of polyvinylidene fluoride and polymethylmethacrylate may be used. Useful flexible visible and infrared light-transmissive substrates also include multilayer film substrates. The multilayer film substrate may have different fluoropolymers in different layers, or may include at least one fluoropolymer layer and at least one non-fluorinated polymer layer. The multilayer film may comprise several layers (e.g., two or more layers), or it may include more than 100 layers (e.g., a total of 100 to 2000 layers or more) have. The different polymers in the different multilayer film substrates can be used in the wavelength range of 300 to 400 nm, for example, as described in U.S. Patent No. 5,540,978 (Schrenk), for example, , 40, or 50% or more) of UV light. Such blends and multilayer film substrates may be useful in providing UV resistant substrates having a lower CTE than the fluoropolymers described above.

Some exemplary weather-resistant sheets, including fluoropolymers, are available, for example, from E.I. TEFZEL ETFE "and" TEDLAR " from EI duPont De Nemours and Co. and Dyneon LLC, Oakdale, Minn. From Dyneon &lt; &gt; ETFE ", "Dyneon THV "," Dyneon FEP ", and "Dyneon PVDF ", from Staunton, From St. Gobain Performance Plastics under the trade designation "NORTON ETFE ", from Asahi Glass under the trade designation" CYTOPS ", and from Denka (Tokyo) Quot; DENKA DX Film "from Kagaku Kogyo KK.

Some useful weather resistant sheets have been reported to be resistant to UV light degradation in the absence of UVA, HALS, and antioxidants. For example, certain resorcinol isophthalate / terephthalate copolyarylates such as those described in U.S. Pat. Nos. 3,444,129; 3,460,961; 3,492,261; And 3,503,779 are reported to be weather-resistant. A certain weatherable multilayer article comprising a layer comprising structural units derived from 1,3-dihydroxybenzene organanedicarboxylate is reported in International Patent Publication WO 2000/061664, and resorcinolic arylate poly Certain polymers containing ester chain members are reported in U.S. Patent No. 6,306,507. A block copolyester carbonate comprising a structural unit derived from at least one 1,3-dihydroxybenzene and at least one aromatic dicarboxylic acid is formed into a layer and the other polymer comprising a carbonate structural unit And layer are reported in U.S. Patent Application Publication No. 2004/0253428. The weather-resistant sheet containing polycarbonate can have a relatively large CTE as compared with, for example, polyester. The CTE of the weather-resistant sheet containing the polycarbonate can be, for example, about 70 ppm / K.

In some or all of the embodiments of the weather resistant sheet or layer described above, the major surface of the weather resistant sheet (e.g., a fluoropolymer) may be treated to improve adhesion to the pressure sensitive adhesive. Useful surface treatments include, for example, electrical discharge (e.g., plasma, glow discharge, corona discharge, dielectric barrier discharge or atmospheric pressure discharge) in the presence of a suitable reactive or non-reactive atmosphere; Chemical pretreatment (e.g., using alkaline solution and / or liquid ammonia); Flame pretreatment; Or electron beam processing. A separate adhesion promoting layer may also be formed between the PSA and the main surface of the weather resistant sheet. In some embodiments, the weather resistant sheet may be a fluoropolymer coated with PSA and then irradiated with an electron beam to form a chemical bond between the substrate and the pressure sensitive adhesive; (See, for example, U.S. Patent No. 6,878,400 (Yamanaka et al.)). Some useful weatherable sheets that have been surface treated are available, for example, from St. Gobain Performance Plastics under the trade designation "Norton ETFE ".

In some embodiments, the weather-resistant sheet has a thickness of from about 0.01 mm to about 1 mm. In some embodiments, the weather-resistant sheet has a thickness of from about 0.05 mm to about 0.25 mm. In some embodiments, the weather-resistant sheet has a thickness of from about 0.05 mm to about 0.15 mm.

Tie Floor

In some embodiments, the tie layer comprises a metal oxide, such as aluminum oxide, copper oxide, titanium dioxide, silicon dioxide, or a combination thereof. As a tie layer, titanium dioxide has surprisingly been found to provide high resistance to delamination in dry delamination and wet delamination tests. Additional options and advantages of the metal oxide tie layer are described in U.S. Patent No. 5,361,172 (Schissel et al.), Which is incorporated herein by reference.

In any of the above-described exemplary embodiments, the tie layer is less than 500 microns in thickness. In some embodiments, the tie layer has a thickness of from about 0.1 micrometer to about 5 micrometers. In some embodiments, it is preferred that the total thickness of the tie layer is greater than 0.1 nanometers, greater than 0.25 nanometers, greater than 0.5 nanometers, or greater than 1 nanometer. In some embodiments, it is preferred that the total thickness of the tie layer is less than 2 nanometers, less than 5 nanometers, less than 7 nanometers, or less than 10 nanometers.

Reflective layer / reflective material

The sun mirror film described herein comprises at least one reflective layer comprising at least one reflective material. The reflective layer (s) (including the reflective material) provide reflectivity. In some embodiments, the reflective layer (s) has a smooth reflective metallic surface that is a mirror surface. As used herein, the term "mirror surface" refers to a surface that induces mirror-like reflection of light, the direction of incoming light and the direction of outgoing light forming the same angle with respect to the surface normal Quot; Although any reflective metal may be used for this purpose, preferred metals include silver, gold, aluminum, copper, nickel, and titanium. In some embodiments, the reflective layer comprises silver.

The prior art reflective layer extends across the entire major surface of the weather resistant layer. In the present invention, the reflective layer (s) do not extend across the entire major surface of the weatherable layer. Any method can be used to create a reflective layer that does not extend across the entire major surface of the weatherable layer.

In some embodiments, the reflective layer is deposited on, or otherwise positioned adjacent to, the weather-resistant layer such that the reflective material does not extend across the entire major surface of the weather-resistant layer. In some embodiments, a portion of the weather-resistant layer is masked during the deposition process to apply the reflective layer only on a predetermined portion of the compliant layer. U.S. Patent Application (Case No. 69866US002, assigned to the assignee of the present invention) provides a more detailed description of this method, which is incorporated herein by reference.

Alternatively or additionally, a reflective material may be deposited on or adjacent to the weather-resistant layer such that the reflective material extends across all or substantially all of the major surface of the weather-resistant layer, and then a portion of the reflective material is removed A reflective layer that does not extend across the major surface can be formed.

The disclosure of the reflective layer / reflective material may be achieved, for example, by sputter coating, evaporation via an e-beam or thermal method, ion-assisted e-beam evaporation, electroplating, spray painting, vacuum deposition, Can be accomplished using a number of coating methods including physical vapor deposition. The metal treatment process is selected based on the polymer and metal used, the cost, and a number of other technical and practical factors. Physical vapor deposition (PVD) of metals is very common in some applications because it can provide the purest metal on a clean interface. In this technique, the target atoms can escape by high energy particle impact and strike them against the substrate to form a thin film. The high energy particles used in the sputter-deposition are generated by glow discharge, or self-sustaining plasma, for example produced by applying an electromagnetic field to an argon gas. In some embodiments, a reflective layer and / or reflective material is applied to the weatherable layer. In some embodiments (not shown in the figures), a reflective layer of reflective material is applied on the tie layer.

Subsequent removal of a portion of the reflective material may be accomplished in a number of ways, for example, by ultrasound, using mechanical removal methods (including, for example, physical removal and laser removal) . A U.S. patent application (Case No. 69677US002, assigned to the assignee of the present invention) provides a more detailed description of this method, which is incorporated herein by reference.

The reflective material or layer (s) is preferably thick enough to reflect the desired amount of light in the solar spectrum. The preferred thickness may vary depending on the composition of the reflective layer and the particular use of the sun mirror film. In some exemplary embodiments, for metals such as silver, aluminum, copper, and gold, the reflective layer is from about 75 nanometers to about 100 nanometers thick. In some embodiments, the reflective layer has a thickness of 500 nanometers or less. In some embodiments, the reflective layer has a thickness of 80 nm to 250 nm. In some embodiments, the reflective layer has a thickness of at least 25 nanometers, at least 50 nanometers, at least 75 nanometers, at least 90 nanometers, or at least 100 nanometers. Additionally, in some embodiments, the reflective layer may have a thickness less than 100 nanometers, less than 110 nanometers, less than 125 nanometers, less than 150 nanometers, less than 200 nanometers, less than 300 nanometers, less than 400 nanometers, or 500 Nm or less. Although not shown in the drawing, two or more reflective layers may be used.

Corrosion resistant layer

The corrosion resistant layer is optional. If included, the corrosion resistant layer may comprise, for example, elemental copper. The use of a copper layer that serves as a sacrificial anode can provide improved corrosion resistance and outdoor weatherability to the reflective article. As another approach, relatively inert metal alloys such as Inconel (iron-nickel alloys) may also be used.

The corrosion resistant layer is preferably thick enough to provide the desired amount of corrosion resistance. The preferred thickness may vary depending on the composition of the corrosion resistant layer. In some exemplary embodiments, the corrosion resistant layer is from about 75 nanometers to about 100 nanometers thick. In another embodiment, the corrosion resistant layer is from about 20 nanometers to about 30 nanometers thick. Although not shown in the drawings, two or more corrosion resistant layers can be used.

In some embodiments, the corrosion resistant layer is less than 500 nanometers in thickness. In some embodiments, the corrosion resistant layer has a thickness of 80 nm to 250 nm. In some embodiments, the corrosion resistant layer is at least 25 nanometers thick, at least 50 nanometers thick, at least 75 nanometers thick, at least 90 nanometers thick, or at least 100 nanometers thick. In addition, in some embodiments, the corrosion resistant layer may have a thickness less than 100 nanometers, less than 110 nanometers, less than 125 nanometers, less than 150 nanometers, less than 200 nanometers, less than 300 nanometers, less than 400 nanometers, or It is less than 500 nanometers.

Adhesive layer

The adhesive layer is optional. The adhesive layer, if present, adheres the multi-layer structure to the substrate (not shown in the figure). In some embodiments, the adhesive is a pressure sensitive adhesive. As used herein, the term " pressure sensitive adhesive "refers to an adhesive that exhibits robust and continuous tack, adhesion to substrates using sub-shrunk, and sufficient cohesive strength to be removable from the substrate. Exemplary pressure sensitive adhesives include those described in International Patent Publication WO 2009/146227 (Joseph et al.), Which is incorporated herein by reference.

Liner

The liner is optional. The liner, if present, protects the adhesive and allows the sun mirror film to be transferred onto the other substrate. Such configurations can then be conveniently packaged for transportation, storage and consumer use. In some embodiments, the liner is a release liner. In some embodiments, the liner is a silicone-coated release liner.

materials

The films described herein can be applied to a substrate by removing the liner 180 (if present) and placing the adhesive layer 170 (if present) adjacent the substrate. The pre-mask layer 110 (if present) is then removed to expose the weather-resistant layer 120 to sunlight. Suitable substrates generally share certain characteristics. Most importantly, the substrate should be sufficiently rigid. Second, the substrate is sufficiently smooth that the texture of the substrate should not be transmitted through the adhesive / metal / polymer stack. As a result, this is advantageous because (1) it enables an optically precise mirror, (2) it has a channel for the penetration of reactive species that can corrode the metal reflective layer or degrade the adhesive (3) to provide controlled and defined stress concentrations in the reflective film-based stack. Third, the substrate is preferably non-reactive with the reflective mirror stack to prevent corrosion. Fourth, the substrate preferably has a surface to which the adhesive durably adheres.

An exemplary description for a reflective film is disclosed in International Patent Publication No. WO04114419 (Schripsema), and WO03022578 (Johnston et al.), With related options and advantages; U.S. Patent Application Publication No. 2010/0186336 (Valente et al.) And 2009/0101195 (Reynolds et al.); And U.S. Patent No. 7,343,913 (Neidermeyer), all of which are incorporated herein by reference in their entirety. For example, the article may be one of a number of mirror panel assemblies, such as those described in co-owned and co-owned US patent application Ser. No. 13 / 393,879 (Cosgrove et al.), . Other exemplary substrates include, for example, metals such as aluminum, steel, glass, or composite materials.

Advantages and embodiments of the present invention are further illustrated by the following examples, and the specific materials and amounts thereof, as well as other conditions and details, recited in these examples should not be construed as unduly limiting the present invention . These embodiments are for illustrative purposes only and are not intended to limit the scope of the appended claims. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values presented in the specific examples are reported as precisely as possible. However, any numerical value inherently contains a predetermined error, which inevitably results from the standard deviation found in their respective test measurements. At the very least, and without wishing to restrict the disclosure of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Also, in these examples, all percentages, ratios, and ratios are by weight unless otherwise indicated.

Example

Test Methods

Neutral salt spray test

ISO 9227: 2006, "Corrosion test in artificial atmospheres - salt, as a% reflective area after various times in salt spray, or simply as a visual observation failure while in salt spray, Corrosion of Comparative Examples and Examples was evaluated according to the procedure outlined in Corrosion tests in artificial atmospheres (Salt spray tests). Visual disruption refers to the first visual indication of corrosion while the sample is in a salt spray.

Percent reflection area

The surface area of the laminated sample, which does not exhibit any signs of discoloration due to corrosion or delamination, was taken as the reflection area for each sample. This area was then reported as a percentage of the initial reflective surface area of the sample. The initial reflective area of the sample was taken as the total surface area of the control sample and for the ultrasonically edge treated sample as the area within the ultrasonic seal. This was determined by making a photocopy of the laminate after the test, and cutting the black portion of the photocopy to weigh it. The corroded area appears to be non-black in the photocopy.

Comparative Example 1

A reflective mirror film (available from 3M Company, St. Paul, MN, under the trade name "Sun Mirror Film SMF-1100") comprising a polymer layer and a metallized layer was applied to a pressure sensitive adhesive After removing the liner, it was laminated onto a painted aluminum substrate having a thickness of approximately 0.02 in (0.05 cm). The aluminum substrate was then cut into 4 inch by 4 inches (10.2 cm x 10.2 cm) samples using a shear cutter. The preliminary mask was removed. Three samples were tested according to the "Neutral Salt Spray Test" described above. The test results are provided in Table 1.

In addition, one 0.9 m x 1.2 m sample was exposed to the above "Neutral Salt Spray Test" for one week followed by two months in the sun and moisture, after which 80% of the surface was 1.3 cm ) Was covered with a tunnel. These data are not reported in Table 1.

Comparative Example 2

(Obtained as "Sun Mirror Film SMF-1100" from 3M Company, St. Paul, MN, USA) containing a polymer layer and a metal-treated layer was prepared by removing the pressure sensitive adhesive liner on the metal- , And about 0.02 inches (0.05 cm) thick. Subsequently, the aluminum substrate was cut into 10.2 cm x 10.2 cm (4 in x 4 in) samples using a shearing cutter. The preliminary mask was removed. All four edges of the sample were covered with a 12.7 mm (0.5 in.) Wide "3M weatherable film ", by affixing a 6.4 mm (0.25 in.) Tape around the front and edge sides of the sample and folding the remaining edge tape tightly to the sample. Quot; Weather Resistant Film Tape " 838 "(available from 3M Company, St. Paul, Minn.). Samples were tested according to the "Neutral Salt Spray Test" above and the samples showed signs of corrosion after two weeks.

Example 1

(Obtained as "Sun Mirror Film SMF-1100" from 3M Company, St. Paul, MN, USA) containing a polymer layer and a metal-treated layer was prepared by removing the pressure sensitive adhesive liner on the metal- , And about 0.02 inches (0.05 cm) thick. Subsequently, the aluminum substrate was cut into 10.2 cm x 10.2 cm (4 in x 4 in) samples using a shearing cutter. The preliminary mask was removed.

The reflective mirror film was welded along its edge using ultrasonic energy as follows. A 3 inch (7.62 cm) air cylinder (BRANSON model "2000X" available from Emerson Industrial Automation, St. Louis, Mo.), a commercially available 1.5 Gain manufactured by the Branson Company an ultrasound welder with a gain titanium booster and a 3.0 gain titanium bar horn was used at a frequency of 20 kHz and a power output of 4 kW. This ultrasonic energy output corresponds to an amplitude of 89 to 99 micrometers (3.5 to 3.9 mils) peak-to-peak. The horn had a welding face of 15 in. X 1.3 in. (6 in. X 0.5 in.). The laminated aluminum sample was plunge welded using a pressure of 140 psi (20 psi), a trigger force of 350 psi (50 lbf), and a weld retention time of 0.15 seconds for each of its four sides.

Samples were tested according to the "Neutral Salt Spray Test" described above, and the results are provided in Table 1.

Example 2

A welded sample was prepared as described in Example 1, except that a pressure of 280 lbs (40 lbf) was used. Samples were tested according to the "Neutral Salt Spray Test" described above, and the results are provided in Table 1.

Example 3

A welded sample was prepared as described in Example 1, except that the polyolefin preliminary mask was not removed. All four sides of a 4 inch by 4 inch sample were pressed at a distance of about 0.125 inches (0.318 cm) from each edge to a pressure of 140 pounds (20 psi) for each side, 350 (50 lbf) of trigger force, and a residence time of 0.15 seconds. Samples were tested according to the "Neutral Salt Spray Test" described above, and the results are provided in Table 1.

Example 4

A laminated aluminum substrate was prepared as described in Example 3, except that a pressure of 240 psi (35 psi) was used and a trigger force was applied for 0.10 seconds on each side of the sample. Samples were tested according to the "Neutral Salt Spray Test" described above, and the results are provided in Table 1.

Example 5

A 254 micrometer (10 mil) thick polyvinylidene fluoride (PVDF) homopolymer film (available under the trade designation "SOLEF 1010" from Solvay Solexis, West Deptford, NJ) ). A PVDF film cut to a width of about 0.1 cm was placed on the mirror film at about 0.125 in (0.318 cm) from the edge. Using the ultrasonic welder described in Example 1, all four edges of a 10.2 cm x 10.2 cm structure were cut at a distance of about 3.18 mm (0.125 in.) From each edge, and at a distance of 480 mm (70 psi) Pressure, trigger force of 2100 ㎪ (300 lbf) for all sides, and 0.09 seconds for all sides. Thus, using this method, a strip of PVDF film was aligned under the horn of an ultrasonic welder and "melted" into the PMMA layer.

Samples were tested according to the "Neutral Salt Spray Test" described above, and the results are provided in Table 1.

Example 6

A 254 micrometer (10 mil) cast film of impact modified PMMA based resin was obtained according to the recommended industry extrusion conditions recommended for such resins. The resin was obtained from Plaskolite of Columbus, Ohio (OPTIX CA-923 UVA2), containing 15% of a two-layer type impact modifier, 1.5% of UV absorber and a melt flow rate of 2.0 To 3.0 (g / 10 min, according to ASTM D 1238 (3.8 / 230)). The film was cut to a width of 0.1 cm, placed on a 10.2 cm x 10.2 cm laminated aluminum-based reflective mirror film face, and a pressure of 480 psi (70 psi) at a distance of about 3.18 mm (0.125 in) , And welded for 0.09 second, 0.13 second, 0.10 second, and 0.10 second for the first, second, third, and fourth sides, respectively, using a trigger force of 2100 ㎪ (300 lbf). Two additional replicate samples (total 3) were prepared and tested, wherein the salt spray test results were the same as the first sample as reported for Example 6 in Table 1. Although not damaging or impacting the tested embodiment, possible weld holes were filled with a narrow impact modified PMMA strip to protect it from impact and damage.

Samples were tested as described in the " Neutral Salt Spray Test "and the results are shown in Table 1.

Example 7

A sample of 10.2 cm x 10.2 cm (4 in x 4 in) laminate was prepared as described in Example 1. In the samples without PSA and liner, all four metal edges were manually scraped mechanically from the metal side of the laminate by a silicon carbide hand tool (12.7 mm (0.5 in) wide blade with square blade). Using this tool, 3.18 mm (0.125 in) of silver was removed from all four edges. After such mechanical removal, the scraped metal side of the laminate was coated with an equal amount of PSA and then the laminate was bonded to the aluminum substrate as described under "Fabricating the aluminum base ".

The samples were tested as described in the " Neutral Salt Spray Test ", and the samples did not show signs of corrosion after 67 days.

In addition, one 0.9 m x 1.2 m sample was exposed to the neutral salt spray test described above for one week followed by exposure to sun and moisture for one year. Even after one year of such exposure, the sample did not show signs of tunneling. These data are not reported in Table 1.

Example 8

A sample of 10.2 cm x 10.2 cm (4 in x 4 in) laminate was prepared as described in Example 1. The sample was then laser abraded to produce a 15 mm x 15 mm square well from about 0.5 to 1.0 in. From the edge of the laminate. A "hurrySCAN 20" scanner (available from Scanlab AG, Munich, Germany) equipped with a telecentric F-Theta Objective (f = 100 mm focal length) A SP-40P-HL laser from SPI Lasers was used. Scanners and lasers were computer controlled. The set values included a wavelength of 1070 nm, a pulse length of 250 ns, a velocity of 500 mm / sec, and a repetition rate of 30 kHz. The laser maximum power was 40 W, but the actual output used in the examples was 50% or 20 W. The laser orientation was through the PMMA side of the laminate. Single or triplet lines were generated by single or triple scans.

Samples were tested as described in the " Neutral Salt Spray Test ", and the samples showed signs of corrosion after 7 days.

Example 9

Samples were prepared as described in Example 8 but laser ablated at 60% power. Samples were tested as described in the " Neutral Salt Spray Test ", and the samples showed signs of corrosion after 21 days.

Example 10

Samples were prepared as described in Example 8, but laser ablated on the aluminum substrate before lamination. Samples were tested as described in the " Neutral Salt Spray Test ", and the samples did not show signs of corrosion after 9 days, at which point the test was stopped.

Example 11

Samples were prepared as described in Example 10 but using 60% power. Samples were tested as described in the " Neutral Salt Spray Test ", and the samples did not show signs of corrosion after 9 days.

Example 12

Ultrasonic In addition to Examples 1-6, ultrasonic welding has also been demonstrated using a knurled anvil. Several null patterns were tried and the optimized null pattern was determined to be a pattern with a pitch of 0.020 inches, a subtractive angle of 90 degrees and a width of 0.64 cm (0.25 in). A "Sun Mirror Film SMF-1100" film (not laminated to the aluminum substrate) with the adhesive side facing the anvil of the null pattern was passed under the bar horn. The horn was oscillating at a frequency of 20 kHz. The welding surface of the horn was 15 cm × 2.5 cm (6 in × 1 in). The horn had a continuous radius of 6.22 cm (2.45 inches) across the welding face of 2.5 inches (1 in.). The amplitude measured at the weld plane was 44.7 micrometers (1.76 mils) peak-to-peak, 75% of the total output. The film speed was 10.7 m / min (35 ft / min) and the force was 667 N (150 lbf).

The samples were tested as described in the " Neutral Salt Spray Test ", and the samples showed less than 5% corrosion after 16 days.

Example 13

Samples were prepared as described in Example 12 except that the amplitude was 87.5% of the total output, the speed was 15 m / min (50 ft / min) and the force was 500 N (112.5 lbf). The samples were tested according to the "Neutral Salt Spray Test ", and the samples did not show signs of corrosion after 16 days.

Example 14

Samples were prepared as described in Example 12 except that the amplitude was 100% of the total output, the speed was 11 m / min (35 ft / min) and the force was 334 N (75 lbf). The samples were tested according to the "Neutral Salt Spray Test ", and the samples showed less than 5% corrosion after 16 days.

All references cited herein are incorporated by reference.

Unless otherwise indicated, all numbers expressing the size, quantity and physical characteristics of the features, as used in this specification and claims, are to be understood as being modified in all instances by the term "about ". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by those skilled in the art using the teachings herein.

As used in this specification and the appended claims, the singular forms "a", "an", and "the" include embodiments having a plurality of referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term "or" is generally used to mean "and / or" unless the content clearly dictates otherwise.

Various embodiments and implementations of the invention are disclosed. The disclosed embodiments are presented for purposes of illustration and are not limiting. The foregoing and other implementations fall within the scope of the following claims. Those skilled in the art will appreciate that the invention may be practiced in other embodiments than those disclosed herein. Those skilled in the art will appreciate that many modifications may be made to the details of such embodiments and implementations without departing from the basic principles of the above-described embodiments and implementations. It is not intended that the invention be unduly limited to the illustrative embodiments and examples disclosed herein, but such embodiments and embodiments are presented by way of example only, and the scope of the present invention is not limited to the patents But is intended to be limited only by the scope of the claims. In addition, various modifications and variations of the present invention will become apparent to those skilled in the art without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined only by the following claims.

Claims (40)

Providing a weather resistant layer having a first major surface and a second major surface;
Depositing a reflective material on the first major surface of the weather resistant layer; And
And removing the portion of the reflective material by ultrasonic waves. 2. The method of claim 1, wherein a portion of the reflective material removed from the weather resistant layer follows at least one edge region of the weather resistant layer. 3. The method of claim 1 or 2, wherein at least one of the edge regions extends from the distal edge of the weather resistant layer to 2 mm above the first major surface. 4. The method of any one of claims 1 to 3, wherein the edge region extends from about 2 mm to about 20 mm from the distal edge of the weather resistant layer onto the first major surface. 5. The method of any one of claims 1 to 4, wherein depositing the reflective material comprises sputter coating, evaporation via an e-beam or thermal method, ion-assisted e-beam evaporation, , At least one physical vapor deposition through electroplating, spray painting, vacuum deposition, and combinations thereof. 6. The method of any one of claims 1 to 5, wherein the reflective material covers at least 98% of the first major surface of the weather resistant layer. 7. A method according to any one of claims 1 to 6, wherein the step of ultrasonically removing the reflective material comprises using a knurl pattern. 8. The method according to any one of claims 1 to 7,
Further comprising the step of ultrasonically removing a portion of the weather resistant layer. 9. The method according to any one of claims 1 to 8,
Further comprising the step of disposing a filler in the area from which the reflective material has been removed. 10. The method of claim 9, wherein the filler is a polymeric material. 11. The method of producing a solar mirror film according to claim 9 or 10, wherein the filler is a thermoplastic material. 12. The method of any one of claims 1 to 11, wherein the weather resistant layer comprises at least one of PMMA, polycarbonate, polyester, multilayer optical film, fluoropolymer, and blend of acrylate and fluoropolymer , A method for producing a solar mirror film. 13. The method of any one of claims 1 to 12, wherein the reflective material comprises at least one of silver, gold, aluminum, copper, nickel, and titanium. 14. The method according to any one of claims 1 to 13,
Further comprising the step of disposing a tie layer between the weather resistant layer and the reflective material. 15. The method of claim 14, wherein the tie layer comprises an adhesive. 16. The method according to claim 14 or 15,
Further comprising the step of ultrasonically removing a portion of the tie layer. 17. The method according to any one of claims 1 to 16,
Further comprising the step of disposing a polymeric material between the weather resistant layer and the reflective material. 18. The method according to any one of claims 1 to 17,
Further comprising the step of disposing a corrosion protection layer adjacent the reflective layer. 19. The method of claim 18, wherein the corrosion protection layer comprises at least one of copper and an inert metal alloy. 20. The method according to any one of claims 1 to 19,
A method of manufacturing a solar mirror film, further comprising the step of placing a solar mirror film in at least one of a concentrated photovoltaic system, a concentrated solar system, or a reflector assembly. Way. Providing a weather resistant layer having a first major surface and a second major surface;
Depositing a reflective material on the first major surface of the weather resistant layer; And
And thermally removing a portion of the reflective material. 22. The method of claim 21, wherein a portion of the reflective material removed from the weather resistant layer follows at least one edge region of the weather resistant layer. 23. The method of claim 21 or 22, wherein at least one of the edge regions extends from the distal edge of the weather resistant layer to 2 mm above the first major surface. 24. The method of any one of claims 21-23, wherein the edge region extends from the distal edge of the weather resistant layer onto the first major surface to about 2 mm to about 20 mm. 25. A method according to any one of claims 21 to 24, wherein the step of depositing the reflective material is performed by sputter coating, evaporation via an e-beam or thermal method, ion-assisted e-beam evaporation, electroplating, spray painting, vacuum deposition And at least one physical vapor deposition through a combination thereof. 26. The method of any one of claims 21 to 25, wherein the reflective material covers at least 98% of the first major surface of the weather resistant layer. 27. The method of any one of claims 21 to 26, wherein the step of thermally removing the reflective material comprises ultrasonically removing the reflective material. 28. The method according to any one of claims 21-27,
Further comprising the step of thermally removing a portion of the weather resistant layer. 29. The method according to any one of claims 21 to 28,
Further comprising the step of disposing a filler in the area from which the reflective material has been removed. 30. The method of claim 29, wherein the filler is a polymeric material. The method of manufacturing a solar mirror film according to claim 29 or 30, wherein the filler is a thermoplastic material. 32. A method according to any one of claims 21 to 31, wherein the weather resistant layer comprises at least one of PMMA, polycarbonate, polyester, multilayer optical film, fluoropolymer, and blend of acrylate and fluoropolymer , A method for producing a solar mirror film. 33. The method of any one of claims 21 to 32, wherein the reflective material comprises at least one of silver, gold, aluminum, copper, nickel, and titanium. 34. The method according to any one of claims 21 to 33,
Further comprising a tie layer between the weather-resistant layer and the reflective material. 35. The method of claim 34, wherein the tie layer comprises an adhesive. 36. The method according to any one of claims 21 to 35,
Further comprising the step of thermally removing a portion of the tie layer. 36. The method according to any one of claims 21 to 36,
Further comprising the step of disposing a polymeric material between the weather resistant layer and the reflective material. 37. The method according to any one of claims 21 to 37,
Further comprising the step of disposing a corrosion protection layer adjacent the reflective layer. 39. The method of claim 38, wherein the corrosion protection layer comprises at least one of copper and an inert metal alloy. 40. The method according to any one of claims 21 to 39,
Further comprising the step of disposing a solar mirror film within at least one of a centralized photovoltaic system, a centralized solar system, or a reflector assembly.

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